Thin walled thermoplastic pressure vessels particularly for carbonated beverages and methods of making same

ABSTRACT

A bottle, particularly for carbonated beverages such as conventional soft drinks and beer, and formed of thin walled, flexible, synthetic plastic parts which are differential pressure formed in heated thermoplastic webs and then severed therefrom, and comprising generally: an upper side wall portion having a neck from which the beverage or the like may be poured, and a generally convex bottom wall for the bottle or vessel having a continuous peripheral flange telescopically received within the lower end of the side wall portion. The external diameter of the upper portion of the flange is slightly greater than the interior diameter of the section of the side wall portion in which it is received so as to be received therein with an interference fit, the parts being friction welded together to dispose friction weld material between the upper portion of the flange and the side wall at the periphery of the convex bottom wall to securely bond the parts together. Another embodiment of the invention is disclosed in which the side wall portion is formed of telescopically interfitted and friction welded upper and lower sections.

United States Patent 91 Jones [54] THIN WALLED THERMOPLASTIC PRESSURE VESSELS PARTICULARLY FOR CARBONATED BEVERAGES [75] Inventor: Elwyn Jones, Beaverton, Mich.

[73] Assigneez- Koehring Company, Milwaukee,

Wis.

22 Filed: on. 12, 1970 21 Appl.No.:79,910

[52] 0.8. CI. ..215/1 C, 150/.5, 156/73, 220/66, 220/67, 229/5.5

[51] Int, Cl. ..B65d 23/00 {58] Field of Sealch.....'....2l5/l C, 1 R; 229/55, 5.8; 156/73; 220/66, 67, 5 R; 150/.5

[ 1 Jan. 23, 1973 Primary Examiner-Leonard Summer Assistant Examiner-Stephen Marcus Att0rney-Learman & McCulloch 57 Q ABSTRACT A bottle, particularly for carbonated beverages such as conventional soft drinks and beer, and formed of thin walled, flexible, synthetic plasticparts which are differential pressure formed in heated thermoplastic webs and then severed therefrom, and comprising generally: an upper side wall portion having a neck from which the beverage or the like may be poured, and a generally convex bottom wall for the bottle or vessel having a continuous peripheral flange telescopically received within the lower end of the sidewall portion. The external diameter of the upper portion of the flange is slightly greater than the interior diameter of the section of the side wall portion in which it is received so as to be received therein with an interference fit, the parts being friction welded together to dispose friction weld material between the upper portion of the flange and the side wall at the periphery of the convex bottom wall to securely bond the parts together. Another embodiment of the invention is disclosed in which the side wall portion is formed of telescopically interfitted and friction welded upper and lower sections.

10 Claims, 10 Drawing Figures PATENTED JAN 23 1975 SHEEI 1 [IF 3 I .497 PATENTEUJAH 23 1975 I 3.712

sum 2 BF 3 PMENTEUJM123 ma 3.712.497

sum 3 or 3 FIG. IO

'1 ram WALLED THERMOPLASTIC raassuaa VESSELS PARTICULARLY FOR CARBONA'IED BEVERAGES BACKGROUND OF THE INVENTION The invention relates broadly to disposable plastic bottles, which can be formed economically at high rates of production, for storing beverages and the like under pressure, and more particularly to a novel vessel pressure without bulging or rupturing. Presently, synthetic plastic bottles, which are manufactured by conventional blow molding methods and have relatively thick and rigid walls to withstand internal pressures which may be generated during the handling of the carbonated beverages contained therein, are being trial or bottle which can withstand considerable internal I dling do not tend to separate the parts, and the friction welding of the lower portion of the flange is avoided so that an inertia type friction weld can be achieved.

BRIEF DESCRIPTION OF THE DRAWINGS Other objects and advantages of the invention will become apparent from a consideration of the following bottle or vessel designed particularly to hold a car-v marketed. It is estimated conservatively that such beer containers must be capable of withstanding internal pressures up to 50 psi and such bottles for beverages such as Pepsi-Cola and Coca-Cola soft drinks must be capable of'withstandingpressures up to75 psi. While these blow molded, thick walled containers are preferable to containers made of other material, because they are light in weight and will not shatter or dent when dropped, still the ultimate in lightness and economy has not been obtained with plastic bottles of one piece, blow molded construction.

SUMMARY E THE INVENTION An object of the present invention is to remedy the shortcomings of the prior art vessels mentioned. In particular, it is an object of the invention to design a vessel or bottle which can be much more economical manufactured by forming parts in a plurality of relatively plastic material, and has been found to be capable of withstanding much greater internal pressures than the maximum it would be required to take, considering the beverages which are to be handled. Briefly, the container includes an upper side wall portion including a neck configured to receivea cap. The side wall portion may be formed of one section, or several teiescopically received annular sections which are friction welded in assembledlrelation, and a convex'bottom wall part is provided having a reversely turned flange which interfits within the lower endof the side wall portion and is of a diameter such that it maybe friction welded in position. The bottle or vessel is particularly designed to facilitate telescoping of the sections to befriction welded for relative axial positioning of the parts to'be friction welded, for avoiding the introduction of plastic fines into the interior of the vessel, and for gripping the various parts of the vessel to permit the friction welding assembly operationsjto be performed. It is the upper portion only of the bottom section flange which is friction welded in positionso that gases generated in hanbonated beverage such as beer;

FIG. 2 is a top plan view thereof;

FIG. 3 is an inverse plan view thereof;

FIG. 4 is a greatly enlarged, fragmentary, sectional, side elevational view taken of the circled area in FIG. 1;

- FIG. 5 is a partly sectional, side elevational view of a second embodiment of the invention in which a three piece bottle for accommodating soft drinks is shown;

FIG. 6 is a top plan view thereof;

FIG. 7 is an inverse plan view thereof;

FIG. 8 is an exploded view showing the three parts of the vessel in separated position; v 7 FIG. 9 is a greatly enlarged, fragmentary, side elevational, sectional view of the area of the bottle encircled in FIG. 5; and I FIG. 10 is a schematic diagram illustrating a system for forming and assembling the vessels.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now more particularly to the accompanying drawings, and in the first instance to FIGS. 1 4, the particular beer container formed is shown in assembled condition as comprising an upper side portion, generally designated 10, and a generally convex bottom section, generally designated 1 l, whichis telescopically received within the lower end of the side wall portion 10 and securely bonded thereto in a manner which will be presently described. The upper end of the side wall portion 10 isfo'rmed with a neck section 12 which may be threaded as shown to receive a conventional cap (not shown), it being understood that an opening 12a is punched in the upper end or top wall of the neck 12 to facilitate pouring of the beverage from the container once the cap (not shown) has been removed.

FIG. 4 particularly illustrates the configuration of a bottom section 11 and the manner in which it interfits with the lower end of the side wall section 10. Each bottom wallsection 11 includes a generally convex bottom wall portion 13', merged with a generally horizontal flat rim portion 13a which in turn merges with a reversely turned flange portion generally designated 14. As will be indicated later, the side wall parts 10 and bottom wall parts 11 are differential pressure formed in relatively thin, thermoplastic material,such as, for instance, clear, transparent polyvinylchloride material. Typically, the wall thickness of the parts will range between 0.018 inches to 0.030 inches in mean wall thickness, when formed.

As FIG. 4indicates, the upper end of annular flange I4 is provided with a curvilinear merging surface 14a which functions as a pilot to facilitate entry of the bottom wall section 11 into the lower end of the side wall portion 10, and it is to be understood that the upper peripheral portion a of the flange 14 is of greater external diameter than the internal diameter of the side wall portion over its extent so as to be received within this portion of the side wall portion 10 with an interference fit. Friction weld material is disposed between the upper portion of flange 14 and the portion of the side wall 10 which it engages over the distance a and securely bonds the bottom wall section 11 around its entire peripheral flange 14 to the side wall portion 10. Both the side wall 10 and the flange 14 are slightly frustoconical in the sense that they slope outwardly at the same angle in a downward direction, as FIG. 4 indicates. Typically the external diameter of flange 14 at the juncture b of bottom 11 and side wall 10 may be 2.608 inches in diameter when the internal diameter of the wall of section 10 at this point is 2.584 inches and the external diameter of the section a of flange 14 is throughout its length typically 0.012 inches in diameter greater than the internal diameter of the section of side wall portion 10 with which it interfits. Stating it differently, the diameters are selected so that there is a 0.012 inch interference fit.

Below the section a the wall 10 has an outset portion 10a which, for instance, may have an internal diameter of 2.624 inches, and which is formed with a series of outwardly projecting vertical ribs 16. Below the ribs 16, a radially out turned shoulder 17 is provided on the lower portion of side wall section 10 leading to a bottom lip portion 18 which is flush with the outer surface of the ribs 16, as will be apparent from FIG. 4. The flange 14 is similarly provided with a radially outturned shoulder 19 leading to a terminal end portion 20 which has inwardly projecting vertically extending ribs 21 formed therein. There is no interference fit between the sections 18 and 20 which can be of the same external and internal diameter, respectively.

Each of the side wall sections 10 and bottom sections 11 can be formed with available thermoforming machinery, such as that described in the present assignees U.S. Pat. No. 3,346,923 and friction welded in assembled relation with apparatus of the character shown in the present assignees U.S. Pat. No. 3,297,504. In the latter patent, punch-out or trim press mechanism is disclosed for severing the container shaped sections from the plastic web in which they are differential pressure formed and, in the instance of each of parts 10 and 11, it is to be understood that such punch-out mechanisms sever the container shaped parts from the web in which they are formed at their open ends. In the case of parts 10 the punch-out mechanism incorporates an additional punch for punching out the openings 12a in the end walls of the neck sections 12. When the parts 10 and 11 are mounted in the part holding sleeves shown in U.S. Pat. 3,297,504 and moved into telescoped relationship to be friction welded together, the stop surfaces 17 and 19 limit the inward telescoping of the parts 10 and 11. Then, when the parts 10 and 11 are relatively rotated in the manner described in the patent to friction weld them together, any fines which result from rubbing of the axially opposed surfaces 17 and 19 have no access to the interior of the vessel or bottle formed. It is thus, important that any axial surfaces which might rub together be disposed at a spaced distance from the juncture b of the bottom wall part 11 and side wall part 10. For the reason that a friction weld exists over the length a, commencing at the juncture b, around the entire periphery of the parts, no gas under pressure can work between the parts 10 and flange 14 to tend to separate them. By limiting the friction weld area to the area a, which is radially spaced out from and axially opposite the concave-convex wall 13. An inertia weld of the character described in U.S. Pat. No. 3,297,504 can be achieved which would not be possible, if the entire flange area 14 were in a state of interference fit with the side wall part 10.

In FIGS. 5 thru 8 an alternative fonn of the invention is illustrated in which the bottom wall section, which I shall also designate 11, is formed in exactly the same manner as described. The side wall section, generally designated 10, is, however, formed of an upper section 10 and a lower section 10". It is to be understood that the lower section 10 is formed at its lower end to interfit with bottom sections 11 in exactly the manner previously described and the same numerals are used to designate the like parts. As will be noted, it is the upper portion 10' which is formed with the neck 12 for receiving a cap (not shown), and has an opening 12a punched therein.

FIG. 9 particularly illustrates the manner in which the parts 10' and 10" are joined together in friction welded condition. As FIG. 9 indicates, the upper end portion of the part 10" is formed with a radially inset shoulder 22 which merges with an inset upper end portion 23 terminating in a radially intumed lip 24. The upper side part 10 has a terminal portion 26 which receives portion 23 and extends flush with the portion of part 10" below shoulder 22, as shown in FIG. 9. Portions 23 and 26 may be vertical as shown or may also-be slightly frustoconical and slope outwardly in a downward direction at a common angle. The rigidity of the vessel is greatly enhanced by providing double wall thickness axially at the locations of wall portions 23 and 26 and the appearance is attractive because of the flush fit. The portion 23 is an interference fit within the portion 26, and an interference fit of 0.012 inches may also be used in this instance. Typically, the external diameter of section 23 may be 2.314 inches at juncture b, for example, when the part 10' in which it engages has an internal diameter of 2.302 inches. This 0.012 interference differential is maintained over the length a of the friction weld which is achieved, there being friction weld material 27 disposed between these surfaces over the length a, as indicated. The wall 23 is provided with an upper curvilinear surface 230, as shown, functioning as a pilot surface to facilitate entry of the part 10 into the part 10'. Because no axially engaging parts are employed on the internal surfaces of the parts, no fines are generated during friction welding which could contaminate the contents of the bottle when it is filled. Ribs 28 provided in each section 10 permit gripping of sections 10 to facilitate friction welding. When assembled in the manner indicated, the bottle formed may have a weight of about 30 grams, which is considerably lighter than are present plastic containers for carbonated beverages.

FIG. 10 is a schematic diagram illustrating a method of making and assembling the container parts for the vessel shown in FIGS. 5 9. Three separate plastic webs 30, 31 and 32 are shown being supplied to three thermoformers 33, 34 and 35, respectively, which operate in the manner indicated in U. S. Pat. No.

3,346,923 to respectively form upper sections in- A termediate sections 10'', and bottom sections 1 1 in the sheets 30 32 respectively. It is to be understood that the sheets 30 and32 may be supplied by an extruder or may be supplied from rolls of plastic sheet or web material, mounted adjacent to the thermoforming machines 33 35 in the usual manner, and which are heated in the thermoforming machines 33 35 until they are deformable. From the thermoforming machines 33 35 the webs 30 32, respectively, proceed to cut-out machines 36 38, respectively, conventionally called trim presses, which may be generally of the construction shown in U. S. Pat. No. 3,297,504 and respectively punch out the parts 10', 10'', and l1 from the webs 30 32. Conveyors 39 move the parts 10 to spin welding machinery 40 of the character disclosed in U.S. Pat. No. 3,297,504, while conveyors 41 are moving the parts 10" to the same spin welding machinery 40. The parts 10' and 10" are relatively telescoped in the friction welding machinery 40, and relatively rotated to securely friction weld them together.-

The trim press37 includes a punch for punching an opening 0 in the closed end wall of each of the parts 10' formed in web 31 which, of course, leaves the lips 24. Lips 24 do not in any material way obstruct the interiors of the bottles formed, and the openings 0 need not be punched with any precision to conform with the internal diameters of the portions 23 of parts 10''.

The parts 11, which are punched out of the web 32 by the trim press 38 proceed to a final friction welding machine 42, also of the character illustrated in U.S. Pat. No. 3,297,504, on a conveyor 43. There they are united with the joined parts 10' and 10" which proceed to the friction welding machine 42 on the conveyor 44. Finally, the fully assembled and securely united bottles leave the friction welder 42 on a conveyor 45 which transfers them to filling and capping machinery which is not shown since it forms no part of the present invention.

. It is to be understood that the drawings and descriptive matter are in all cases to be interpreted as merely illustrative of the principles of the invention, rather than as limiting thesame in any way, since it is contemplated that various changes may be made in various elements to achieve like results without departing from the spirit of the invention or the scope of the appended claims.

lclaim: p

. l. A' thin-walled, flexible, thermoplastic synthetic plastic pressure vessel, particularly for carbonated beverages, comprising: an annular, differential-pressure-formed, side wall portion having a neck at its upper end out which the beverage or the like may be poured; and a differential-pressure-formed bottom for said vessel having a concavo-convex bottom 'wall and a continuous peripheral flange telescopically received within the lower end of said. side wall to provide a lower end portion for said vessel of double wall thickness; the external diameter of a portion of said flange being of slightly greater diameter than the interior diameter of the section of the side wall portion in which it is received so as to be received therein with an interference fit; and friction weld material radially spaced out from and axially opposite said concave-convex wall between said portion of said flange and side wall portion at the periphery of said bottom wall, securely bonding the bottom wall to the side wall portion.

2. The vessel of claim 1 in which said flange and side wall have stop surfaces controlling the extent to which said bottom wall flange is telescoped into the lower end of said side wall portion.

3. The vessel of claim 2 in which said stop surfaces comprise outwardly extending shoulders on both the flange and side wall portion spaced a distance below said friction weld material.

4. The combination defined in claim 3 in which externally projecting vertical ribs are formed in the side wall portion between the friction weld material and shoulders.

5. The combination defined in claim 4 in which internally projecting vertical ribs are formed in the flange between the shoulders and lower end thereof.

6. The combination defined in claim 1 in which said flange is reversely turned and includes a curvilinear upper portion functioning as a pilot surface to aid entry of said bottom wall into the side wall portion.

7. The combination defined in claim 1 in which said side wall portion includes separate upper and lower annular sections with the upper end of the lower section having an external diameter greater than that of the lower end of the upper section'so as to be received therein with an interference fit; and friction weld material is provided between the said upper end of the lower section and lower end of the upper section to securely bond them.

8. The combination defined in claim 7 in which the upper end of the lower section has a radially intumed portion functioning as a pilot surface to aid entry of the lower section into the upper section.

9. The combination defined in claim 1 in which axially extending ribs are formed in a section of said flange below said friction weld material, which is of no greater diameter than the adjacent part of the side wall portion and is not in interference fitting relation therewith.

10. A thin walled flexible, thermoplastic synthetic plastic pressure vessel, particularly for carbonated beverages, comprising: an annular, differential pressure formed, side wall portion having a neck at its upper end out which the beverage or the like may be poured; and a differential pressure formed bottom for said vessel, having a concavo-convex bottom wall and a continuous generally vertically extending peripheral flange telescopically received by the lower end of said side wall to provide a lower end portion for said vessel of double wall thickness; the external diameter of the upper portion of said flange being of slightly greater diameter than the interior diameter of the section of the side wall portion by which it is received so as to be received with an interference fit; friction weld material between the upper portion of said flange and side wall portion at the periphery of said bottom wall securely bonding the bottom wall to the side wall portion, and vertical telescoping stop surfaces, comprising radially extending shoulder means, on the flange and side wall portion, below said friction weld material. 

1. A thin-walled, flexible, thermoplastic synthetic plastic pressure vessel, particularly for carbonated beverages, comprising: an annular, differential-pressure-formed, side wall portion having a neck at its upper end out which the beverage or the like may be poured; and a differential-pressure-formed bottom for said vessel having a concavo-convex bottom wall and a continuous peripheral flange telescopically received within the lower end of said side wall to provide a lower end portion for said vessel of double wall thickness; the external diameter of a portion of said flange being of slightly greater diameter than the interior diameter of the section of the side wall portion in which it is received so as to be received therein with an interference fit; and friction weld material radially spaced out from and axially opposite said concavo-convex wall between said portion of said flange and side wall portion at the periphery of said bottom wall, securely bonding the bottom wall to the side wall portion.
 2. The vessel of claim 1 in which said flange and side wall have stop surfaces controlling the extent to which said bottom wall flange is telescoped into the lower end of said side wall portion.
 3. The vessel of claim 2 in which said stop surfaces comprise outwardly extending shoulders on both the flange and side wall portion spaced a distance below said friction weld material.
 4. The combination defined in claim 3 in which externally projecting vertical ribs are formed in the side wall portion between the friction weld material and shoulders.
 5. The combination defined in claim 4 in which internally projecting vertical ribs are formed in the flange between the shoulders and lower end thereof.
 6. The combination defined in claim 1 in which said flange is reversely turned and includes a curvilinear upper portion functioning aS a pilot surface to aid entry of said bottom wall into the side wall portion.
 7. The combination defined in claim 1 in which said side wall portion includes separate upper and lower annular sections with the upper end of the lower section having an external diameter greater than that of the lower end of the upper section so as to be received therein with an interference fit; and friction weld material is provided between the said upper end of the lower section and lower end of the upper section to securely bond them.
 8. The combination defined in claim 7 in which the upper end of the lower section has a radially inturned portion functioning as a pilot surface to aid entry of the lower section into the upper section.
 9. The combination defined in claim 1 in which axially extending ribs are formed in a section of said flange below said friction weld material, which is of no greater diameter than the adjacent part of the side wall portion and is not in interference fitting relation therewith.
 10. A thin walled flexible, thermoplastic synthetic plastic pressure vessel, particularly for carbonated beverages, comprising: an annular, differential pressure formed, side wall portion having a neck at its upper end out which the beverage or the like may be poured; and a differential pressure formed bottom for said vessel, having a concavo-convex bottom wall and a continuous generally vertically extending peripheral flange telescopically received by the lower end of said side wall to provide a lower end portion for said vessel of double wall thickness; the external diameter of the upper portion of said flange being of slightly greater diameter than the interior diameter of the section of the side wall portion by which it is received so as to be received with an interference fit; friction weld material between the upper portion of said flange and side wall portion at the periphery of said bottom wall securely bonding the bottom wall to the side wall portion, and vertical telescoping stop surfaces, comprising radially extending shoulder means, on the flange and side wall portion, below said friction weld material. 